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Ect 204
Ect 204
J. Schonek Y. Nebon
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no. 204
LV protection devices and variable speed drives
(frequency converters)
Jacques SCHONEK Graduate engineer from ENSEEIHT with a doctorate in Engineering from the University of Toulouse, he was involved in designing variable speed drives for the Telemecanique brand from 1980 to 1995. He then became manager of the Harmonic Filtering group. He is currently responsible for Electrotechnical Applications and Networks in the Advanced Design Office of Schneider Electrics electrical distribution management.
Yves NEBON He joined Merlin Gerin in 1969 and worked for 14 years in the low voltage design offices while continuing his professional training, gaining several diplomas and achieving the title of engineer. He then held a number of different positions in the Low Voltage Division. Since 1995 he has been responsible for the marketing, management and development of the Merlin Gerin brand LV electrical distribution product ranges within Schneider Electric.
Contents
1 Frequency converter type variable speed drives for asynchronous motors 2 Devices providing protection against overcurrents 3 Protection of persons 1.1 Description 1.2 Need for appropriate protection devices 2.1 Protection devices integrated in drives 2.2 Protection devices external to drives 3.1 Risks connected with insulation faults 3.2 3.3 3.4 3.5 4 Protection devices to be used with drives 5 Special phenomena Summary of earthing systems Use of RCDs according to the earthing system Earth fault protection devices integrated in drives Insulation faults and variable speed drives p. 4 p. 7 p. 8 p. 9 p. 11 p. 12 p. 14 p. 14 p. 15 p. 19 p. 20 p. 22 p. 23 p. 25 p. 26 p. 28 p. 28 p. 29 p. 30
(summary table) 5.1 High-frequency leakage currents 5.2 5.3 5.4 5.5 Leakage currents on power-up Fault at the drive output with a TT or TN system Fault at the drive output with an IT system Fault current with a DC component
Bibliography
1.1 Description
Purpose The purpose of frequency converter type variable speed drives is to supply 3-phase asynchronous motors in such a way as to obtain operating characteristics which are radically different from those obtained in normal use (motors supplied directly from the power supply), with constant amplitude and frequency. The table in figure 1 lists the advantages of these devices. Principle This consists of supplying the motor with a voltage wave with variable amplitude and frequency, while keeping the voltage/frequency ratio more or less constant. This voltage wave is generated by an electronic power device whose simplified schematic is shown in figure 4.
Asynchronous motor in normal use Starting current Very high, around 6 to 8 times the nominal current in rms value and 15 to 20 times in peak value High and not controlled, around 2 to 3 times the nominal torque Tn
with variable speed drive Limited in the motor (in general: around 1.5 times the nominal current) Around 1.5 times the nominal torque Tn and controlled for the whole of the acceleration
Starting torque Ts
Starting
Sudden: its duration only depends on the Smooth, gradual and controlled characteristics of the motor and the driven (for example, linear speed ramp) load (resistive torque, inertia) Varies slightly according to the load (close to the synchronous speed Ns) High, around 2 to 3 times the nominal torque Tn Relatively complex, requiring protection devices and a special schematic Easy only after the motor has stopped Yes, with overtorque (resistive torque > Tm), or if voltage drops See fig. 2 Variation possible from zero up to a value greater than the synchronous speed Ns High, available across the whole speed range (around 1.5 times the nominal torque) Easy Easy No See fig. 3
Speed
Maximum torque Tm
Electrical braking Reversing Risk of stalling Motor operation in the torque-speed plane
Fig. 1 : comparison of the operating characteristics, showing the advantages of frequency converter type variable speed drives.
T Tm
Rectifier
Inverter
Motor
M
Ts Tn
Fig. 2 : speed-torque diagram for a motor supplied directly. The operating zone of the motor in the torquespeed plane is limited to the green part of the curve.
T Tm
Tn
reference, etc) and the measurement of the electrical values (line voltage, motor current). The PWM principle used in the inverter bridge consists of applying a series of voltage pulses to the motor windings, whose amplitude is equal to the DC voltage supplied by the rectifier. The width of the pulses is modulated so that a variable amplitude AC voltage is created. The curves shown in figure 5 are examples of phase-to-phase voltage and of current in one of the machine windings (assuming delta-connected windings).
(/s)
Fig. 3 : speed-torque diagram for a motor supplied via a frequency converter. The operating zone of the motor in the torque-speed plane is shown in green.
I load V load
The converter consists of: c a single-phase or 3-phase diode rectifier bridge combined with a capacitor, forming a DC voltage source (DC Bus), c an inverter bridge, generally with IGBTs (Insulated Gate Bipolar Transistors), supplied with a DC voltage, which generates an AC voltage wave with variable amplitude and frequency using the Pulse Width Modulation (PWM) technique, c a control unit providing the conduction commands to the IGBTs according to instructions given by the operator (run command, direction of operation, speed
t (s)
0.005
0.01
0.015
0.02
Characteristics of the current drawn by the drive c Waveform v In the case of a 3-phase power supply The rectifier bridge combined with the filter capacitor draws a non-sinusoidal current from the line supply. The shape of this current is shown in figure 6 and its harmonic spectrum is shown in figure 7 . The typical harmonic distortion value THD is 40%. It should be noted that this distortion is obtained by adding line chokes that cause a voltage drop of between 3 and 5%. In the absence of these
line chokes, the current distortion is higher: it can reach 80% if there is no inductance in the drive. v In the case of a single-phase power supply The current drawn is shown in figure 8 and its spectrum in figure 9. The typical harmonic distortion value THD is 80%. It should be noted that this distortion is again obtained by adding a line choke that causes a voltage drop of between 3 and 5%. In the absence of this line choke, the current distortion is higher: it can exceed 100% if there is no inductance in the drive.
t (s)
t (s)
0.02
0.04
0.02
0.04
Fig. 6 : current drawn and phase voltage of the line supply (3-phase supply).
Fig. 8 : current drawn and phase voltage of the line supply (single-phase power supply).
9 11 13 15 17 19 21 23 25 Harmonic order
Fig. 7 : spectrum of the current drawn from the line supply (3-phase supply).
Fig. 9 : spectrum of the current drawn from the line supply (single-phase supply).
c Variation of the line current according to the motor operating point Since the fundamental current drawn by the drive is practically in phase with the voltage, the current is proportional to the electric power drawn from the line supply. If we disregard the efficiency, this current is therefore proportional to the mechanical power supplied by the motor. The mechanical power is equal to the product of the torque times the speed. Thus, at reduced speed the mechanical power is low. As a result, the current drawn from the line supply by the drive is low when the motor operates at low speed, even if the motor produces a high torque and takes a high current.
Standard references Two standards are particularly concerned with the design of variable speed drives: c IEC 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC product standard. c EN 50178 Electronic equipment for use in power installations. Conformity to this standard authorizes CE marking under the European Low Voltage directive. It should be noted that this standard also gives details for installing these products.
The protection devices commonly used against overcurrents (circuit-breakers or fuses) are mainly provided to deal with two situations: c To protect an installation against any risk of short-circuit. c To avoid the risks resulting from a circuit overload or an operating current that exceeds
the capacities of the conductors (busbars and cables) and the control and protection equipment Variable speed drive technology enables some of these functions to be provided electronically.
Rectifier
Inverter
Motor
and the motor, as well as any dangerous overcurrent when the line voltage returns to its normal value. c Overvoltages at the line supply power frequency: This avoids possible destruction of their components. c Loss of a phase (for 3-phase drives): because the single-phase supply which replaces the 3-phase supply triggers an increase of the current drawn. Operation of the integrated protection devices If there is a fault, all these devices lock the drive and bring the motor to a freewheel stop. The power supply is then cut by the line contactor (its opening is controlled by a relay integrated in the drive).
Circuit breaker: c short-circuit protection, c isolation for maintenance. Contactor: c automatic on-off, c power supply breaking in the event of a fault. Drive: c soft start, c variable speed control, c motor protection, c overload protection (wiring and switchgear).
Irms = I1 1+ THD2
thus, when THD = 40 %, Irms = 1.08 I1 . Since the fundamental current I1 is practically in phase with the voltage, the typical value of the current drawn by the drive, when it supplies a motor operating at its nominal point (constant torque application), is calculated using the formula:
Motor
These combinations (circuit-breaker, contactor and drive) offered by manufacturers are called motor combinations. Due to the protection devices integrated in the drives, these combinations naturally provide type 2 coordination if there is a short-circuit downstream of the drive.
Where: Pmot: motor nominal power U: phase-to-phase voltage mot: motor efficiency drive: drive efficiency
M
Circuit-breaker Contactor
Two special cases c Motors supplied in parallel In this case the overload protection integrated in the drive cannot protect each motor. This means that one of the motors could have an overload, although the current drawn by all the motors together does not exceed the drive nominal current. The motors must therefore be protected individually by a thermal overload relay (see fig. 12 ). It is however recommended that the overload protection integrated in the drive should remain active, in order to protect the cables upstream. c Integral drive overload protection disabled For certain applications for which continuity of operation is essential, the drive overload protection can be disabled. The cables and switchgear, which must be protected upstream, must therefore have an overload protection associated with the motor combination circuit-breaker (see fig. 13 ). Oversizing of the cable and the switchgear by 20% is recommended in this situation.
Circuit-breaker
Contactor
3 Protection of persons
If
N PE
Uf
If
RB
RA
N PE
In the event of contact with a frame which is accidentally energized (Uf) the danger threshold is fixed by the safety limit voltage UL . Thus where: RA = earthing resistance of the installation frames, RB = earthing resistance of the neutral, the operating threshold (In) of the protection device must be such that: Uf = RA .In i UL and then In i UL / RA. (For more details, please refer to Cahier Technique no. 114)
RB
RA
RB
RA
RB
RB
c all frames in the installation are connected to one another and earthed. In the IT system, the first insulation fault does not require breaking to take place, which enables the installation to continue to operate normally. However, this fault must be detected, signaled and then repaired before a second insulation fault occurs on another live conductor, which would then require an immediate trip. This rule gives the IT system the best continuity of service (see also Cahier Technique no. 178). Need for special detection methods The value of the insulation fault current between phase and earth (in common mode) depends on the earthing system. Its value is often too low to be detected and eliminated by conventional overcurrent protection devices (thermal or magnetic protection of a circuit-breaker), as is the case with the TT and IT systems. Two devices are designed particularly for protecting persons: Residual Current Devices RCDs - and Permanent Insulation Monitors PIMs -. c Residual Current Devices v Principle of RCDs This is illustrated in figure 17. If there is no insulation fault, the algebraic sum of the currents in the live conductors is zero and the toroid is not subjected to any magnetomotive force. If there is an insulation fault, this sum is no longer zero and the fault current creates a magnetomotive force in the toroid that generates a current in its coil. If the current exceeds a fixed threshold for a period longer than the optional time delay, an opening command is transmitted to the breaking device. For further details, see Cahier Technique no. 114: Residual current devices in LV.
v Types of RCD Standard IEC 60755 distinguishes three types of residual current protection device: AC: For sinusoidal AC currents A: For AC currents with a DC component (see fig. 18 ). These devices are suitable for detection of rectified single-phase currents. B: For DC currents. These devices are suitable for all types of current and are necessary, in particular, for rectified 3-phase currents. c PIMs The principle of a PIM consists of injecting an AC or DC voltage between the line supply and the earth (see fig. 19 ). The measurement of the current crossing the monitor is used to calculate the insulation resistance when this is a DC current, and that of the line supply/earth impedance when this is an AC current. These measurements associated with threshold devices authorize different alarms, for example that for the gradual reduction of insulation for the purpose of planned maintenance, or for an earth fault requiring rapid intervention (before the second fault).
6 mA
= 90
= 135
Fig. 18 : waveforms which characterize type A RCDs.
I0
Wave shaping
Rectifier
Inverter
Motor
M
N
If
RB PE
circumstances. In fact, the impedance of the fault may limit the current to a value that is below the drives protection threshold. This is generally the case with the TT system. A 300 mA RCD is therefore necessary.
In the case of an IT system, the first fault does not cause current to circulate and the drive continues to operate normally.
On the DC bus B
Fig. 21 : voltages present in the event of direct contact with TT and TN-S systems.
Fig. 22 : various situations specific to a line supply with an IT system which has an insulation fault and a person in direct contact.
In the three situations specific to the IT system shown in figure 22, no automatic break protection can be applied: the fault current cannot be distinguished from the normal
operating current. This underlines the importance that installers must give to the wiring of these machines in order to ensure the basic precaution, i.e. insulation of live parts.
Notes: v The same is found for each of these situations when the two faults (insulation and direct contact) are swapped. v When a number of drives are powered via the same line supply, the DC buses of the different drives can be considered as being at the same voltage. Faults on different drives therefore have the same consequences as if they were located on one drive.
Indirect contact c TT and TN-S systems The indirect contact situations are shown in figure 23 . c IT system With this system the presence of two simultaneous faults must be taken into account. The table in figure 24 gives the various possible faults and their consequences.
Situation
Effect (risk)
Relevant protection Relevant with a TT system protection with a TN-S system Overcurrent protection placed upstream
Overcurrent across a diode of the rectifier bridge. The fault current is a rectified current. (Risk of irreparable damage)
Overcurrent across Internal in the drive a diode of the or rectifier bridge and RCD an IGBT. (Risk of irreparable damage depending on the type of short-circuit protection integrated in the drive)
Internal in the drive or overcurrent protection placed upstream, but a very long cable downstream of the drive may mask the fault, and an RCD is therefore recommended
Situation
A
Overcurrent across a diode of the rectifier bridge and an IGBT (Risk of irreparable damage depending on the type of short-circuit protection integrated in the drive) Short-circuit on the DC bus (Risk of irreparable damage to the rectifier bridge)
Internal in the drive or overcurrent protection placed upstream, but a very long cable downstream of the drive may mask the fault. Overcurrent protection placed upstream
Short-circuit at the terminals of an IGBT (Risk of irreparable damage to the opposite IGBT depending on the type of short-circuit protection integrated in the drive)
Fig. 24 : various situations with two dead shorts or low impedance faults on an IT system.
c Special case of motors supplied via two separate circuits each containing a drive, where the frames have separate earth connections. When an installation supplies a number of devices that are a long way away from one another, the load frames are often connected with separate earth connections. The impedance of the circuit through which the fault current runs is thus increased by the resistance of the two earth connections concerned. The condition required for the protection of persons (compliance with maximum breaking times) can no longer be met by the short-circuit protection devices. The usual solution, which is very simple both to design and install, is to use RCDs (see Cahier Technique no. 178) placed at the start of each
circuit containing a separate earth connection (see fig. 25 ). These RCDs must not be disturbed by the passage of a DC component.
PIM
M
Fig. 25 : positioning of RCDs in an IT system to protect two circuits with separate earth connections.
The following table summarizes the preceding sections, listing the protection functions provided by the drive, and if necessary the addition of
devices external to the drive such as circuitbreakers, thermal overload relays, and RCDs.
Protection to be provided Cable overload Motor overload Drive overheating Overvoltage Undervoltage Phase break Upstream short-circuit Internal fault
Protection generally provided by the drive Yes = (1) Yes = (2) Yes Yes Yes Yes
Circuit-breaker (short-circuit trip) Circuit-breaker (short-circuit and overload trip) Self-protection RCD u 300 mA RCD i 30 mA
5 Special phenomena
The purpose of this section is to analyze the special phenomena connected with the operation
M
Cy Cs
Drive
M
Cr Cy Cc Cs Cm
Characteristics These currents may reach an instantaneous value of several amps and an rms value of several dozen or several hundred milliamps. The spectrum and amplitude of these currents depend both on the PWM frequency (between 1 and 20 kHz) and the installation characteristics: c power supply: line impedance, earthing system, c type and length of the motor cable (shielded, not shielded, protective earth), c motor rating, The shape and spectrum of the HF currents at the drive input (when there is no fault), for a PWM at 4 kHz, are shown in figures 28 and 29 .
(A) 0.3
0.2
0.1
- 0.1
- 0.2
- 0.3
0.0
0.01
0.02
(s)
(A) 0.06
0.05
0.04
0.03
0.02
0.01
10
15
(kHz)
Their effect: risk of disturbance of RCDs c Undesired tripping These currents may cause malfunctioning of the residual current devices (RCD) when they flow through conductors surrounded by the measurement toroid. The measurement of the residual current may therefore be disturbed, in particular when the drive motor connection cable is very long and/or the capacitances between phases and earth are high (see fig. 30 ).
Solution The measurement device must therefore include a filtering circuit so that only the low-frequency component of the signal is taken into account (see fig. 31 ). Additional precautions, given at the end of this Cahier Technique, may be necessary in certain extreme situations.
Fig. 31 : RCD integrating filtering of HF currents (Vigirex RH99M and RH99P Merlin Gerin brand).
V2
M
V1
Frequency factor F
15
10
Voltages V1 and V2 are responsible for circulating any fault current that may occur, as shown in figure 35 .
1 50/60
V1
V2
Fig. 33 : variation of the cardiac fibrillation threshold as a function of the frequency (according to IEC 60479-2).
Shape of the fault current If there is a dead short to earth at the drive output, with a TN system, the overcurrent trips the internal drive protection or the overcurrent protection devices placed upstream.
The fundamental frequency of voltage V1, between the neutral of the 3-phase supply and the central point of the rectifier, is 150 Hz (see fig. 36 ).
Its shape is shown in figure 38 . This fault current also contains the HF currents described in the preceding sections, but not included here in order to simplify the illustrations.
V 100 80 60 40 20 0 -20 -40 -60 -80 -100 0 0.01 0.02 0.03 0.04 t (s) 0.5 0.4 0.3 0.2 0.1 0 -0.1 -0.2 -0.3 -0.4 -0.5 0 0.01 0.02 0.03 0.04 t (s) A
Voltage V2 (see fig. 37 ), between the central point of the rectifier and one output phase is the result of PWM. It therefore contains a lowfrequency component equal to the drive output frequency (40 Hz in this example) and a component at the PWM frequency (1 kHz in this example).
As shown in figure 39 , the amplitude of the various components changes as a function of the motor operating frequency: c The total rms value of the current remains constant, as does the 150 Hz component. c Components at the motor supply frequency and the PWM frequency vary in opposite ways.
V 400 300 200 100 0 -100 -200 -300 -400 0 0.01 0.02 0.03 0.04
100 50 0 0 10 20 30 40 50 60 Total rms value Hz mA 300 250
t (s)
200 150
This results in a fault current containing all of the following components: c 150 Hz, c drive output frequency, c modulation frequency, and their harmonics.
The shape of the fault current for a single-phase power supply is shown in figure 40 . Note that there is a 50 Hz component and not a 150 Hz component as with a 3-phase supply.
Solution The complex shape of the fault current requires the use of a type A RCD (see fig. 41 ).
Fig. 41 : example of a type A RCD suitable for use with an LV circuit-breaker (C60-300 mA Vigi unit Merlin Gerin).
M
V1 Z
Vz
V 400 300 200 100 0 -100 -200 -300 -400 0 0.01 0.02 0.03 0.04 t (s)
M
Rb
Fig. 46 : current in the event of a fault on the braking resistor, for a single-phase supply and a fault resistance of 1 k.
A 0.5 0.4 0.3 0.2 0.1 0 -0.1 0 0.01 0.02 0.03 t (s) 0.04
Solution The protection devices must remain operational despite this DC component. If an insulation fault is possible on the DC bus, or on the braking resistor circuit, a type B RCD must be used when the drive has a 3-phase supply. When the drive has a single-phase supply, a type A RCD should be used. Practical rule for using RCDs c In the first situation, with an IT system, illustrated by figure 47 , the fault current has a DC component. The RCDa used to provide protection against direct contact must therefore be sensitive to this type of current. c In the second situation (see fig. 48 ), two RCDs are connected in cascade. If there is a fault on the DC bus, the fault current may not be sufficiently high to trip RCD2. Conversely, this current, which has a DC component, may be sufficiently high to saturate the measurement toroid of RCD1, preventing it from tripping if there is a fault on another feeder.
Fig. 45 : current in the event of a fault on the braking resistor, for a 3-phase supply and a fault resistance of 1 k .
RCDb
RCD1
RCD2
RCDa
c The following rule is therefore used: If the fault current may have a DC component, a type A or B RCD is necessary, depending on the type of power supply. Thus all the RCDs in which this current may circulate should be identical type A or type B RCDs. This condition
is essential in particular in the following situations: v when these RCDs are installed in series, v in IT systems, since the RCDs may be affected by double faults occurring on different feeders.
Based on the following principles: c for the use of overcurrent protection devices (short-circuit and overload) covered in section 2, c for the protection of persons, covered in section 3, c then the special phenomena described in the previous section,
this section gives practical recommendations that answer the question: how can I provide correct protection for a circuit containing variable speed drives?
Earthing system TT Type B, low (or IT with frames not sensitivity connected together) (u 300 mA) Earthing system IT
[*] The insulation fault is similar to a short-circuit. Tripping must normally be performed by the short-circuit protection device, but the use of an RCD is recommended if there is a risk of overcurrent protection devices not tripping.
Fig. 49 : type of RCD depending on the earthing system and the required protection.
Special recommendations: c only connect one drive per RCD, c provide an RCD as an additional protection
M
PIM
Bibliography
Products standards c IEC 60479: Guide to the effects of current passing through the human body. c IEC 60755: General requirements for residual current operated protective devices. c IEC 60947-2: Low voltage switchgear - Part 2: Circuit-breakers. c IEC 61008, EN 61008-1 et 61008-2: Residual current operated circuit-breakers for household and similar use. c IEC 61009, EN 61009-1 et 61009-2: Residual current operated circuit-breakers with integral overcurrent protection for household and similar use. c IEC 61800-3: Adjustable speed electrical power drive systems - Part 3: EMC product standard. c EN 50178: Electronic equipment used in power installations. c UTE C 60-130: Dispositifs de protection courant diffrentiel rsiduel. c NF C 61-420: Petits disjoncteurs diffrentiels. c NF C 62-411: Matriel de branchement et analogues, disjoncteurs diffrentiels pour tableaux de contrle des installations de premire catgorie.
Installation standards c IEC 60364: Electrical installations of buildings. Schneider Electric Cahiers Techniques c Residual current devices in LV. R. CALVAS, Cahier Technique no. 114. c Protection of people and uninterruptible power supplies. J-N. FIORINA, Cahier Technique no. 129. c Earthing systems in LV. B. LACROIX and R. CALVAS, Cahier Technique no. 172. c Earthing systems worldwide and evolutions. B. LACROIX and R. CALVAS, Cahier Technique no. 173. c Disturbances of electronic systems and earthing systems. R. CALVAS, Cahier Technique no. 177. c The IT earthing system (unearthed neutral) in LV. F. JULLIEN and I. HERITIER, Cahier Technique no. 178. c Cohabitation of high and low currents. R. CALVAS and J. DELABALLE, Cahier Technique no. 187.
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